Software Output Switching - IQ Corporation · configuration dual-chassis configuration I/O...

Application Solution

Software Output Switching

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1 Publication 1756-AP001A-US-E - December 1999

2 Software Output Switching

Important User Information %HFDXVH�RI�WKH�YDULHW\�RI�XVHV�IRU�WKH�SURGXFWV�GHVFULEHG�LQ�WKLV�SXEOLFDWLRQ��WKRVH�UHVSRQVLEOH�IRU�WKH�DSSOLFDWLRQ�DQG�XVH�RI�WKLV�FRQWURO�HTXLSPHQW�PXVW�VDWLVI\�WKHPVHOYHV�WKDW�DOO�QHFHVVDU\�VWHSV�KDYH�EHHQ�WDNHQ�WR�DVVXUH�WKDW�HDFK�DSSOLFDWLRQ�DQG�XVH�PHHWV�DOO�SHUIRUPDQFH�DQG�VDIHW\�UHTXLUHPHQWV��LQFOXGLQJ�DQ\�DSSOLFDEOH�ODZV��UHJXODWLRQV��FRGHV�DQG�VWDQGDUGV�

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ATTENTION

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Publication 1756-AP001A-US-E - December 1999

Software Output Switching 3

How to Implement This Solution

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Overview of Software Switching

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No

Yes

Inhibit the connections of this controller to the output modules

Uninhibit the connections of this controller, which the peer controller may have inhibited

Is this controller faulted? Yes

No

Is this controller in Remote Run mode?

Read the status of the connections to the peer controller and local CNB

Is the connection to the peer controller faulted?

Yes

No

Is the connection to the local CNB good (not faulted)?

Yes

Get the status of the peer controller

Is the peer controller in program mode?

Yes

No

Inhibit the peer controller

Is the peer controller in Fault mode?

Yes

No

Wait x second(s) (Delay depends on the size of the system.)

Uninhibit the connections of this controller to the output modules and take over control

Get the fault code of the output modules

Does the peer controller own the output modules?

Yes Inhibit the connections of this controller to the output modules

No

end

No

Connection to the local chassis may be broken



Switch Over Delay

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Design the System for Multiple Controllers

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Controller Placement

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EXAMPLE 6LQJOH�&KDVVLV�&RQILJXUDWLRQ

ControlLogix chassis with:• two Logix5550 controllers• 1756 CNB module• 1756 ENET module

ControlLogix chassis with:• 1756 CNB module• 1756 input modules

ControlLogix chassis with:• 1756 CNB module• 1756 output modules

ControlNetnetwork

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ControlLogix chassis with:• 1756 CNB module• 1756 input modules• 1756 ENET module

ControlLogix chassis with:• 1756 CNB module• 1756 output modules

ControlNetnetwork

42184

ControlNet network

ControlLogix chassis, each with:• one Logix5550 controller• two 1756 CNB modules

ENET

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I/O Placement

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Communication Networks

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For this type of communications:

Use this network:

single-chassis configuration

dual-chassis configuration

I/O ControlNet network for any remote I/O

ControlNet network for all I/O

controller-to-controller backplane of the chassis ControlNet network:• the same network

that is used for I/O communications

or• a separate network

software interface (e.g., RSLogix 5000 software, MMI software)

Either of these networks:• ControlNet• Ethernet

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Electrical Wiring

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If you want to: Then:

minimize cost A. Purchase one 1756 Ethernet module.B. Install the module in a chassis

containing remote I/0.transition to a hardware redundancy system when it becomes available

protect against the failure of an Ethernet module

A. Purchase two 1756 Ethernet modules.

B. Install one module in each chassis that contains a controller

ATTENTION

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Develop the Project for the Initial Controller

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Configure I/O

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ATTENTION

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Create Programs and Routines

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In this task: Create this program:

Name: Description:

Controller Fault Handler Fault_Program Handles recoverable major faults

the continuous task of the project

Switch_Over Monitors the peer controller and takes over control when required



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Create User-Defined Data Types

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In the program: Create this ladder routine:

Name: Description:

Fault_Program Inhibit_Outputs When the controller faults, inhibits the output modules so the peer controller can take over control

Switch_Over Switch_Over_Logic Monitors the peer controller and initiates a take over of control if required

Ownership_Status Checks for a conflict in the ownership of output modules, which signals that the peer controller has established connections to the modules

Take_Over_Control Uninhibits the output modules, enabling the controller to control the outputs

Inhibit_Outputs Inhibits the output modules

For this program: Assign this routine as the main routine:

Fault_Program Inhibit_Outputs

Switch_Over Switch_Over_Logic

Name: MODULE

Description: Stores attributes of the MODULE object

Members:

Name: Data Type: Style:

FaultCode INT Hex

Mode INT Binary



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Create Tags

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Name: CONTROLLER_DEVICE

Description: Stores the attributes of the CONTROLLERDEVICE object

Members:

Name: Data Type: Style:

Vendor INT Decimal

ProductType INT Decimal

ProductCode INT Decimal

Revision INT Decimal

Status INT Binary

SerialNumber DINT Decimal

DeviceNameLength SINT Decimal

DeviceName SINT[32] Decimal

Scope: Tag Name: Type: Style: Description:

controller Inhibit_Reset INT[3] Decimal Values that uninhibit the connections of a controller

Inhibit_Reset_IO_Map_State INT[3] Decimal Holding values for message

Inhibit_Set INT[3] Decimal Values that inhibit all the connections of a controller

Inhibit_Set_IO_Map_State INT[3] Decimal Holding values for message

Peer CONTROLLER_DEVICE na Information about peer controller

Peer_Dummy_Consume DINT Decimal Dummy tag to establish connection with peer controller

Peer_Dummy_Produce DINT Decimal Dummy tag to establish connection with peer controller

Peer_Inhibit MESSAGE na Inhibits all connections of the peer controller

Peer_Read_Status MESSAGE na Gets information about peer controller

This_Uninhibit MESSAGE na If connections were inhibited by the peer controller, uninhibits all connections of this controller



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Produce this tag: For this many consumers:

Peer_Dummy_Produce 1

For this tag property: Specify:

Name Peer_Dummy_Consume

Tag Type Consumed

Controller <name of peer controller>

Remote Tag Name Peer_Dummy_Produce

RPI value of the NUT for the ControlNet network

Data Type DINT

In this array element: Enter:

Inhibit_Reset[0] 1

Inhibit_Reset[1] 7

Inhibit_Reset[2] 2#0000_0000_0000_0001

In this array element: Enter:

Inhibit_Set[0] 1

Inhibit_Set[1] 7

Inhibit_Set[2] 2#0000_0000_0000_0101



�� Create the following program-scoped tags for the Switch_Over program:

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Enter Logic

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Switch_Over Ownership DINT Decimal Status of connections to output modules

Peer_Connection MODULE na Information about connection to peer controller

Peer_Delay TIMER na Delays take over until connections from peer are inhibited.

Peer_Failed BOOL Decimal Connection to peer has failed.

Peer_Faulted BOOL Decimal Peer controller is faulted.

Peer_In_PROG BOOL Decimal Peer controller is in program mode.

Peer_OK BOOL Decimal Peer controller is operational.

This_In_REMOTE BOOL Decimal Key is in remote position.

This_Status INT Binary Mode of controller


Fault_Program <name> MODULE na Information about connection to module

If the chassis contains: Then enter:

only output and communication modules

for the ControlNet Bridge module in the chassis, a rung from Step 2a. on page 15

both input and output modules for each output module in the chassis, a rung from Step 2b. on page 15



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Set system valueCIP Object class MODULECIP Object name Outputs_1Attribute name ModeSource Outputs_1.Mode 2#0000_0000_0000_0000

SSV

Get system valueCIP Object class MODULECIP Object name CNB_2Attribute name ModeDest CNB_2.Mode 2#0000_0000_0000_0000

GSV

CNB_2.Mode.2

Set system valueCIP Object class MODULECIP Object name CNB_2Attribute name ModeSource CNB_2.Mode 2#0000_0000_0000_0000

SSV

Inhibits the connection to the ControlNet Bridge module (1756-CNB) that is specified in the CIP Object name parameter of the GSV and SSV instructions, which inhibits the entire chassis:

• Gets the mode attribute of the module and stores it in the mode member of a tag with the same name as the module• Sets bit 2 of the mode member, which indicates that the controller should inhibit its connection to the module• Sends the new mode value to the mode attribute, which inhibits the connection

42095

000 - Controller_1:MainTask:SwitchOver:Inhibit_Outputsapp aids\Software Switchover\Controller_1.ACD 10/21/1999 11:16:16 AM Page 1der Logic Listing - Total number of rungs: 2

Get system valueCIP Object class MODULECIP Object name Outputs_1Attribute name ModeDest Outputs_1.Mode 2#0000_0000_0000_0000

GSV

Outputs_1.Mode.2


SSV

Get system valueCIP Obje t lass MODULE

GSV

Inhibits the connection to the module that is specified in the CIP Object name parameter of the GSV and SSV instructions:• Gets the mode attribute of the module and stores it in the mode member of a tag with the same name as the module• Sets bit 2 of the mode member, which indicates that the controller should inhibit its connection to the module• Sends the new mode value to the mode attribute, which inhibits the connection

42095



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SSV

Get system valueCIP Object class MODULECIP Object name CNB_2Attribute name ModeDest CNB_2.Mode 2#0000_0000_0000_0000

GSV

UCNB_2.Mode.2

Set system valueCIP Object class MODULECIP Object name CNB_2Attribute name ModeSource CNB_2.Mode 2#0000_0000_0000_0000

SSV

Uninhibits the connection to the ControlNet Bridge module (1756-CNB) that is specified in the CIP Object name parameter of the GSV and SSV instructions, which uninhibits the entire chassis:

• Gets the mode attribute of the module and stores it in the mode member of a tag with the same name as the module• Clears bit 2 of the mode member, which indicates that the controller should not inhibit its connection to the module• Sends the new mode value to the mode attribute, which uninhibits the connection

42098

000 - Controller_1:MainTask:SwitchOver:Take_Over_Controlapp aids\Software Switchover\Controller_1.ACD 10/21/1999 11:14:01 AM Page 1der Logic Listing - Total number of rungs: 2

Get system valueCIP Object class MODULECIP Object name Outputs_1Attribute name ModeDest Outputs_1.Mode 2#0000_0000_0000_0000

GSV

UOutputs_1.Mode.2


SSV

Get system valueCIP Obje t lass MODULE

GSV

Uninhibits the connection to the module that is specified in the CIP Object name parameter of the GSV and SSV instructions:• Gets the mode attribute of the module and stores it in the mode member of a tag with the same name as the module• Clears bit 2 of the mode member, which indicates that the controller should not inhibit its connection to the module• Sends the new mode value to the mode attribute, which uninhibits the connection

42098



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000 - Controller_1:MainTask:SwitchOver:Switch_Over_Logicapp aids\Software Switchover\Controller_1.ACD 10/21/1999 11:11:52 AM Page 1der Logic Listing - Total number of rungs: 14

Get system valueCIP Object class CONTROLLERDEVICECIP Object name Attribute name StatusDest This_Status 2#0000_0000_0000_0000

GSV

This_Status.12

This_Status.13

This_In_REMOTE

This_In_REMOTE

ENDN

Type - CIP GenericM C t l Thi U i hibit

MSG42096

Gets the Status attribute of the CONTROLLERDEVICE object. If bits 12 and 13 are on, this controller is in a remote mode.

Attribute name StatusDest This_Status 2#0000_0000_0000_0000

This_Status.12

This_Status.13

This_In_REMOTE

This_In_REMOTE

ENDNER

Type - CIP GenericMessage Control This_Uninhibit ...

MSG

Get system valueCIP Obj t l MODULE

GSVGet system valueCIP Obj t l MODULE

GSV42096

When the controller is in Remote Run mode, uninhibits all the connections of this controller. Connections are typically uninhibited, however, in this application solution, another controller may have inhibited all the connections of this controller. To execute this type of CIP generic message, the keyswitch of this controller must be in the Remote position.

In this text box or drop-down list: Type or select:

Message Type CIP Generic

Service Code 4

Object Type 69

Object ID 1

Object Attribute leave blank

Source Inhibit_Reset

Num Of Elements 6

Destination Inhibit_Reset_IO_Map_State

...



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In this text box or check box: Type or select:

Path 1, <slot number of this controller>

Cache Connections Select [✓] the check box.

This_In_REMOTE

ENDNER

Type - CIP GenericMessage Control This_Uninhibit ...

MSG

Get system valueCIP Object class MODULECIP Object name PeerAttribute name FaultCodeDest Peer_Connection.FaultCode 16#0000

GSVGet system valueCIP Object class MODULECIP Object name CNB_1Attribute name FaultCodeDest CNB_1.FaultCode 16#0000

GSV

Not EqualSource A Peer_Connection.FaultCode 16#0000Source B 0

NEQ

Peer_Failed

/Peer_Read_Status.EN

ENDN

Type - CIP GenericMessage Control Peer Read Status

MSG42096

Monitors the connections to the peer controller and the local ControlNet Bridge module. (The dummy produced and consumed tags establish the connection with the peer controller.) If the fault code for the connection to the peer controller is not equal to zero, the peer controller is not operational. The peer controller may have a non-recoverable fault, power to the chassis of the controller may have been interrupted, or a cable to the chassis may be broken.

Not EqualSource A Peer_Connection.FaultCode 16#0000Source B 0

NEQ

Peer_Failed

/Peer_Read_Status.EN

ENDNER

Type - CIP GenericMessage Control Peer_Read_Status ...

MSG

Peer.Status.4

Peer.Status.5

Peer.Status.6

Peer_In_PROG

Peer_In_PROG

ENDN

Type - CIP GenericMessage Control Peer Inhibit

MSG42096

Continuously gets all the information contained in the CONTROLLERDEVICE object of the peer controller. If bits 4, 5, and 6 of the Status attribute are on, the peer controller is in Program mode.

...




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Service Code 1

Object Type 1

Object ID 1


Source leave blank

Num Of Elements 0

Destination Peer

In this text box or check box: Perform this action:

Path A. Click Browse ... B. Select the peer controller.


DNER

Message Control Peer_Read_Status ...

Peer.Status.4

Peer.Status.5

Peer.Status.6

Peer_In_PROG

Peer_In_PROG

ENDNER

Type - CIP GenericMessage Control Peer_Inhibit ...

MSG

Peer.Status.10

Peer.Status.4

Peer.Status.6

Peer_Faulted

42096

If the peer controller is in Program mode, inhibits all of the connections of that controller. This lets this controller take over ownership of the output modules.

...




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Service Code 4

Object Type 69

Object ID 1


Source Inhibit_Set

Num Of Elements 6

Destination Inhibit_Set_IO_Map_State

In this text box or check box: Perform this action:

Path A. Click Browse ... B. Select the peer controller.


Peer_In_PROG

ENDNER


MSG

Peer.Status.10

Peer.Status.4

Peer.Status.6

Peer_Faulted

Peer_In_PROG

ENTimer On DelayTON

42096

If bits 4, 6, and 10 of the CONTROLLERDEVICE Status attribute for the peer controller are on, the peer controller is in Faulted mode and experiencing a recoverable major fault. The Controller Fault Handler of the peer controller will inhibit the connections of that controller to the output modules so this controller can take over control.



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Peer_In_PROG

ENDNER


MSG

Peer.Status.10

Peer.Status.4

Peer.Status.6

Peer_Faulted

Peer_In_PROG

Peer_Faulted

ENDN

Timer On DelayTimer Peer_DelayPreset 1000Accum 0

TON

Peer_Delay.DN

Peer_Failed

EqualSource A CNB_1.FaultCode 16#0000Source B 0

EQU

Jump to SubroutineRoutine name Take_Over_Control

JSR

/Peer_Faulted

/Peer_In_PROG

/Peer_Failed Peer_OK 42096

If the peer controller is in Program mode or Fault mode, starts a time delay while the connections of the peer controller are being inhibited. If the peer controller is not operational (its connection has failed) all of its connections are already broken, so no delay is required. This controller takes over control of the output modules when either of these conditions occur:

• The time delay is done.• The connection to the peer controller is failed but the connection to the ControlNet Bridge module in the same chassis as this controller is

good (i.e., no fault code for the CNB module).

Peer_Failed

EqualSource A CNB_1.FaultCode 16#0000Source B 0

EQU

/Peer_Faulted

/Peer_In_PROG

/Peer_Failed

Peer_OK

42096

If the peer controller is not in Fault mode or Program mode and the connection to the peer controller is not faulted, flags the peer controller as operational (OK)



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000 - Controller_1:MainTask:SwitchOver:Switch_Over_Logicapp aids\Software Switchover\Controller_1.ACD 10/21/1999 11:11:52 AM Pagder Logic Listing - Total number of rungs: 14

Jump to SubroutineRoutine name Ownership_StatusReturn par Ownership

JSR

Peer_OK

EqualS A O hi

EQUJump to SubroutineR i I hibi O

JSR 42097

Checks for a conflict in ownership of each output module. If there is a conflict for each module, returns the value of 9999, which indicates that the peer controller owns (controls) each output module

der Logic Listing - Total number of rungs: 14

Jump to SubroutineRoutine name Ownership_StatusReturn par Ownership

JSR

Peer_OK

EqualSource A Ownership 0Source B 9999

EQUJump to SubroutineRoutine name Inhibit_Outputs

JSR

42097

If the peer controller is operational and owns each output module, inhibits the connections from this controller to the output modules

000 - Controller_1:MainTask:SwitchOver:Ownership_Statusapp aids\Software Switchover\Controller_1.ACD 10/21/1999 11:15:10 AM Page 1der Logic Listing - Total number of rungs: 4

Get system valueCIP Object class MODULECIP Object name Outputs_1Attribute name FaultCodeDest Outputs_1.FaultCode 16#0000

GSVGet system valueCIP Object class MODULECIP Object name Outputs_2Attribute name FaultCodeDest Outputs_2.FaultCode 16#0000

GSV

EqualSource A Outputs 1 FaultCode

EQUEqualSource A Outputs 2 FaultCode

EQUMoveSource 9999

MOV42099

Gets the FaultCode attribute of the module that is specified in the CIP Object name parameter of the GSV instruction and stores it in the mode member of a tag with the same name as the module. There is one GSV instruction for each output module.



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EqualSource A Outputs_1.FaultCode 16#0000Source B 262

EQUEqualSource A Outputs_2.FaultCode 16#0000Source B 262

EQUMoveSource 9999 Dest Ownership 0

MOV

Not EqualSource A Outputs 1.FaultCode

NEQNot EqualSource A Outputs 2.FaultCode

NEQMoveSource 1111

MOV42099

If the fault code for each output module equals 262 (16#0106), the peer controller owns the modules. (I.e., The peer controller has established a connection to each module.) Moves 9999 into the Ownership tag.

EqualSource A Outputs_1.FaultCode 16#0000Source B 262

EQUEqualSource A Outputs_2.FaultCode 16#0000Source B 262

EQUMoveSource 9999 Dest Ownership 0

MOV

Not EqualSource A Outputs_1.FaultCode 16#0000Source B 262

NEQNot EqualSource A Outputs_2.FaultCode 16#0000Source B 262

NEQMoveSource 1111 Dest Ownership 0

MOV

ReturnReturn par Ownership

RET42099

If the fault code for each output module does not equal 262 (16#0106), the peer controller does not own the modules. (I.e., The peer controller has not established a connection to each module.) Moves 1111 into the Ownership tag.

Not EqualSource A Outputs_1.FaultCode 16#0000Source B 262

NEQNot EqualSource A Outputs_2.FaultCode 16#0000Source B 262

NEQMoveSource 1111 Dest Ownership 0

MOV

ReturnReturn par Ownership

RET

42099

Returns the value of the Ownership tag to the main routine. (The value of the Ownership tag is still available to all routines in this program even without passing the parameter. The parameter is used to indicate which routine controls the value of the Ownership tag.)



Develop the Project for the Second Controller

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Additional Programming

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Tune the System for Efficient Switch Over

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Adjust the Time Delay

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Future ControlLogix Redundancy Solution

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high-speed fiber optic link

ControlNetnetwork

ControlLogix chassis with:• 1756-CNB module• 1756 I/O modules• additional communication modules, as

required (e.g., 1756-ENET module)

42197

ControlLogix chassis, each with identical sets of:• one or more Logix5555 controllers• 1756-CNB modules• a single 1757-SRM module

CNB

L55

L55

SRM

CNB

L55

L55

SRM

CNB

CNB

additional I/O chassis, as required



Hardware Requirements

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System Configuration

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Software Switching Versus Hardware Redundancy

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Attribute: Software Switching: Hardware Redundancy:

special hardware • duplicate controller chassis• may require additional network to pass

data between the primary and secondary controllers

• duplicate controller chassis• Logix5555 controllers• enough extra controller RAM for two

copies of all data (usually requires larger memory cards)

• 1757-SRM modules and fiber optic cable

special programming Yes, to perform these actions:• synchronize data• detect failures• switch control of outputs

No, hardware detects failure and switches control automatically

project maintenance two projects to maintain, each requiring a manual download to the appropriate controller

one project, automatically cross-loaded from the primary controller to the secondary controller

effect on program scan time • Extra logic increases scan time.• Both controllers monitor inputs

simultaneously.• Both controllers scan logic independently

(no synchronization).

• Primary controller waits until end of the scan to send data to second controller.

• Secondary controller does not scan logic until it takes over control from the primary controller.

online program changes Yes, each project requires a manual update. Yes, edits are automatically sent to the secondary controller.

online data changes Yes, each project requires either a manual update or logic to copy changes to the secondary controller.

Yes, data changes are automatically sent to the secondary controller.

Forcing Yes, place forces in one controller at a time. To ensure forces remain, place forces in both controllers.

Forces in the primary controller are automatically sent to the secondary controller.

data synchronization • Each project requires logic to copy information from the primary controller to the secondary controller.

• Other systems may need to perform dual writes to update both controllers at the same time.

After each program scan, changes of data in the primary controller are automatically sent to the secondary controller.

controller failure detection time varies with each application essentially immediate because the hardware detects failures

switch over time ≈ 250 ms

switch over if controller:• faults• fails• losses communications

Yes, if programmed automatically

switch over if controller enters Program mode

No

1756 I/O modules in controller chassis

Yes, but not easily No



1756-M02AE motion modules in controller chassis

No No

1756-ENET module in controller chassis

Yes, but external device must handle dual addresses.

No, must reside in a chassis of remote I/O off of a ControlNet network

1756-DHRIO module in controller chassis

• no RIO• DH+, if external device can accommodate

dual addresses

1756-DNB module in controller chassis

Yes, but not easily

Attribute: Software Switching: Hardware Redundancy:


Software Output Switching - IQ Corporation · configuration dual-chassis configuration I/O...

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